Motor Controller Can With Metal Heat Sink Insert

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Solution Overview

Problem

Conventional electric motors face challenges in effectively managing thermal heat and electromagnetic interference (EMI) within the controller compartment, which can lead to inefficiencies and potential damage due to inadequate heat dissipation and EMI suppression.

Innovation Solution

The electric motor incorporates a metal heat sink insert within the controller can, made of thermally conductive material, which is strategically positioned to enhance heat transfer and EMI dissipation, using a thermally insulative end plate and strategically placed fasteners for efficient heat and EMI management.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If conventional methods (openings and fins in the can) are used for heat dissipation, then heat exchange is improved, but structural integrity and EMI shielding are compromised

Engineering Contradiction:

Improveheat dissipationVSAvoidEMI shielding

Core Design Contradiction:

TemperatureVSObject-affected harmful factors

Solution Approach 1:

The heat dissipation function is segmented from the controller can structure by introducing a separate metal insert. The insert contains the heat exchange features (fins or surfaces) while the can maintains its intact EMI shielding. This separates the thermal management function from the structural/EMI function, resolving the contradiction between heat dissipation and EMI shielding integrity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The metal insert acts as an intermediary component between the electronic components and the external environment. It provides a thermal conduction path from the components to the can's exterior without requiring modifications to the can's EMI-shielding structure. The insert mediates the heat transfer while preserving the can's electromagnetic interference protection.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Object-affected harmful factors

If component-based EMI suppression (chokes, capacitors, filters) is added, then EMI emissions are reduced, but device complexity and cost increase

Engineering Contradiction:

ImproveEMI emissionsVSAvoidcomponent count

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The EMI suppression function is extracted from the traditional component-based approach and integrated into the controller can structure itself. The metal insert and can configuration provide inherent EMI filtering through their physical and electrical properties, eliminating the need for separate choke, capacitor, and filter components. This reduces device complexity while maintaining EMI suppression effectiveness.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The controller can is designed to perform multiple functions simultaneously: structural housing, EMI shielding, and thermal management. The metal insert adds EMI suppression capability without requiring additional dedicated EMI components. This multi-functionality approach reduces overall device complexity by consolidating functions into fewer components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Temperature

If a metal heat sink insert is added to the controller can, then heat exchange is significantly improved, but manufacturing complexity increases

Engineering Contradiction:

Improveheat exchange efficiencyVSAvoidmanufacturing process

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The metal insert is merged with the controller can assembly through integration techniques that simplify manufacturing. The insert can be formed as a single piece and attached using standard fastening methods, combining the thermal management function with the existing can structure without requiring complex multi-step manufacturing processes. This merging approach maintains ease of manufacture while achieving superior heat exchange.

Inventive Principle:

Principle #5Merging (Combining)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This configuration significantly improves heat exchange and reduces EMI emissions, maintaining optimal operating temperatures and minimizing the risk of damage to electronic components, while also simplifying manufacturing processes and reducing costs.

Implementation Method 1

The controller can includes a metal insert thermally connected to the electronic component

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

The end plate comprises a thermally insulative material having a thermal conductivity at least four (4) times less than that of the thermally conductive material

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS10715010B2Motor controller can with synthetic housing and metal heat sink

Publication Date: 2020.07.14 NIDEC MOTOR CORP

AI summary

An electric motor including a rotor, a stator, a motor housing having a controller can, and a controller having an electronic component disposed within the controller can. The controller can includes an insert comprising thermally conductive metal for exchanging heat with an external heat sink space.